engine MITSUBISHI GALANT 1989 Service Repair Manual

BACKUP
Service Manual
GRLRNT
1989-1990-1991-1992-1993
Volume 1
Chassis & Mechanical
FOREWORD
This Service Manual has been prepared with thelatest service information available at the time of
publication. It is subdivided into various group cate-
gories and each section contains diagnostic, dis-
assembly, repair, and installation procedures along
with complete specifications and tightening ref-
erences. Use of this manual will aid in properly per-
forming any servicing necessary to maintain or res-
tore the high levels of performance and reliability
designed into these outstanding vehicles.
This BACKUP DSM manual is to be used DNLY as
a SACKUP. please DIJ NOT REDISTRIBUTEWHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed
DWNa GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your
original
manual was lost or
destroyed.) Please
See
README.TXT
or
README.HTML

for additional
information.
1kyou.
- Gjmpiemym_ay&?h
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WE SUPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION THROUGH
Nallonal lnsrltule forAU~~~v3~;VPCT:VE
EXCELLENCE naiLcorn
MITSUBISHIMOTOR SALES OF AMERICA. Inc.
Mltsublshl Motors Corporat!on reserves the right to make changes indesign or to make additions to or Improvements In Its products
wlthout~mposng any obllgatlons upon Itself to install them on its productspreviously manufactured
0 1992 Mitsubishi Motors CorporationRcprintedinUSA
GROUP INDEXMOOAA-
General.........................................................
Engine...........................................................
Fuel................................................................
Cooling.........................................................
Intake and Exhaust..............................
Emission Control....................................
Clutch............................................................
Manual Transaxle..................................
Automatic Transaxle............................
Propeller Shaft........................................
Front Axle..................................................
Rear Axle....................................................
Wheel and Tire.......................................
Power Plant Mount..............................
Front Suspension...................................
Active-Electronic
Control Suspension..............................m
A
Rear Suspension....................................&
Service Brakes.........................................
Parking Brakes........................................
Alphabetical Index.................................
NOTE: Electrical system Information is contained in
Volume 2 “Electrical” of this paired Service Manual.
For overhaul procedures of engines or transmissions,
refer to the separately issued Engine
Service Manual
or Manual/Automatic Transmission Service Manual.

00-l
GENERAL
CONTENTS
GENERAL DATA AND SPECIFICATIONS.....23
HOWTOUSETHISMANUAL......................
3
Definition of Terms ......................................3
ExplanationofCircuitDiagrams..................7
Explanation of
ManualContents .................4
Explanation of the Troubleshooting
Guide .............................................................
6
Model
Indications .........................................3
Scope of Maintenance, Repair and
Servicing Explanations
..................................
3
Troubleshooting .............................................3
LUBRICATIONANDMAINTENANCE............
34
MAINTENANCE SERVICE............................... 39
AirCleanerElement
.....................................39
Automatic
Transaxle
.....................................43
Ball Joint and Steering Linkage Seals ........45
Brake Hoses................................................. 45
Disc Brake Pads ........................................... 44
Drive Belt (For Water Pump and
Generator) .......................................................
41
Drive
Shaft Boots .........................................45
Engine Coolant
............................................. 44
Engine Oil .....................................................
41
Engine Oil Filter ...........................................41
Exhaust System
............................................ 45
FuelHoses
...................................................39
Fuel System
.................................................39
Manual Transaxle ..........................................42
RearAxle......................................................45
Rear Drum Brake Linings and
RearWheel Cylinders
..................................44
Spark
Plugs...................................................40
Timing Belt...................................................40
MASTER
TROUBLESHOOTING.....................28
PRECAUTIONS
BEFORESERVICE................15
RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIESTABLE..................35
SCHEDULED
MAINTENANCETABLE ...........38
SPECIAL HANDLING INSTRUCTIONS
FOR AWD MODELS
.......................................20
TABLE OF MAIN SEALANTS
AND
ADHESIVES ............................................46
TIGHTENING TORQUE
................................... 27
TOWING
ANDHOISTING ..............................17
VEHICLE
IDENTIFICATION .............................8
Chassis Number ...........................................
11
EngineModel
Stamping
...............................12
Theft Protection ............................................12
Vehicle Identification Code Chart Plate.......
8
Vehicle Identification Number List
..............8
Vehicle Identification Number Location .......
8
Vehicle Information
CodePlate...................1 1
Vehicle SafetyCertificationLabel................12

GENERAL - How to Use This Manual00-3
HOW

TO USE THIS MANUALMOOBMTO
SCOPE OF MAINTENANCE, REPAIR AND
DEFINITION OF TERMS
SERVICING EXPLANATIONS STANDARD VALUE
This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair
and servicing of the subject model. Unless other-
wise specified, each service procedure covers all models. Procedures covering specific models are
identified by the model codes, or similar designation
(engine type, transaxle type, etc.). A description of
these designations is covered in this unit under “VEHICLE IDENTIFICATION”.
SERVICE ADJUSTMENT PROCEDURES
“Service Adjustment Procedures” are procedures
for performing inspections and adjustments of
particularly important locations with regard to the
construction and for maintenance and servicing, but
other inspections (for looseness, play, cracking,
damage, etc.) must also be performed.
SERVICE PROCEDURES
The service steps are arranged in numerical order and attentions to be paid in performing vehicleservice are described in detail in SERVICE POINTS.
TROUBLESHOOTING
Troubleshootinqs are classified into master trou-
bleshooting and group troubleshooting and located
as follows:
The master troubleshooting is prepared when the trouble symptom relates to two or more groups and
given in MASTER TROUBLESHOOTING.
The group troubleshooting guide is prepared for causes of problems related to that individual group
only; a troubleshooting guide is prepared for each
appropriate group. Indicates the value used as the standard for judging
the quality of a part or assembly on inspectian or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly must be kept functionally or in strength. It is a value
established outside the range of standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and adjustment procedures, and so they can be
com- pleted
in a shorter time).
CAUTION
Indicates the presentation of information particularly
vital to the worker during the performance of maintenance and servicing procedures in order to
avoid the possibility of injury to the worker; or
damage to component parts, or a reduction of
component or vehicle function or performance, etc.
MODEL INDICATIONS
The following abbreviations are used in this manual for classification o\
f model types.
M/T . Indicates the manual transaxle, or models equipped with the manual\
transaxle.
A/T: indicates the automatic transaxle, or models equipped with the automati\
c transaxle.
MFI: Indicates the multiport
fuel injection, or engines equipped with the
multiport fuel injection.
SOHC: Indicates an engine with the single overhead camshaft, or a model \
equipped with such an engine.
DOHC: Indicates an engine with the double overhead camshaft, or a model \
equipped with such an engine.
Turbo: Indicates an engine with turbocharger, or a model equipped with s\
uch an engine. Non-Turbo: Indicates an engine without turbocharger, or a model equipped\
with such an engine.FWD: Indicates the front wheel drive vehicles.
AWD: Indicates the all wheel drive vehicles. ABS: Indicates the anti-lock braking system or models equipped with the \
anti-lock braking system.

00-4GENERAL - How to Use This Manual
EXPLANATION OF MANUAL CONTENTSIndicates procedures to
be performed before the
work in that section is
started, and procedures
to be performed after
the work in that section
is finished.
Maintenance and Servicing Procedures
(1) A diagram of the component parts is provided near the front of each section in
order to give the reader a better under-
standing of the installed condition of
component parts.
(2) The numbers provided within the diagram indicate the sequence for maintenance
and servicing procedures; the symbol
mindicates a non-reusable part; the tighten-
ing torque is provided where applicable. l Removal steps:
The part designation number corres-
ponds to the number in the illustration
to indicate removal steps.
l Disassembly steps: The part designation number corres-
ponds to the number in the illustration
to indicate disassembly steps.
l Installation steps: Specified in case installation is impossi-
ble in reverse order of removal steps.
Omitted if installation is possible in
reverse order of removal steps.
8 Reassembly steps: Specified in case reassembly is im-
possible in reverse order of disassem-
bly steps.
Omitted if reassembly is possible in reverse order of disassembly steps.
Classificationsof Major Maintenance/
Service Points
When there are major points relative to mainte-
nance and servicing procedures (such as essential
maintenance and service points, maintenance and
service standard values, information regarding the
use of special tools, etc.), these are arranged
together as major maintenance and service points
and explained in detail.
*+ : Indicates that there are essential points for
removal or disassembly.
I)+ : Indicates that there are essential points forinstallation or reassembly. necessary. In this exam-
ple, sealant is applied
(where indicated) to the
I---
Symbols for Lubrication, Sealants and
Adhesives
4 . . . . .Grease
(multipurpose grease unless there is Information
concerning the locations for lubrica-
tion and for application of sealants and adhesives
is provided, by using symbols, in the diagram of
component parts or on the page following the
component parts page, and explarned.
a brand or type specified)
4 . . . . Sealant or adhesive
a. . . . .Brake fluid. automatic transmission
fluid or air conditioner compressor oil
a. . . . . Engine oil or gear oil
. . .Adhesive tape or butyl
rubber tape

00-8GENERAL - Vehicle Identification
VEHICLE IDENTIFICATIONMOOCA-
VEHICLE IDENTIFICATION NUMBER LOCATION
The vehicle identification number
(V.I.N.) is located on a plate
attached to the left top side of the instrument panel.
/ OOAOOSO
VEHICLE IDENTIFICATION CODE CHART
P+zE
All vehicle identification numbers contain 17 digits. The vehiclenumber is a code which tells country, make, vehicle type, etc.
\ \\L\.u 5th 6th 7th
r\ 8th 9th 10th
Digit DigitDigitDigit Digit
Digit
I
3rdDigit
/
4thDigit
/ 2nd
Digit
Line
H- Galant
FWD
1 StDigit
Body
6-4 doorSedan
Price
class4-High5-Premium Engine
Check
digits*Model
year
Make Vehicle
typeOthersPlantSerialnumber
Country
OkazakiPlant
D-2.0 dm3(122cu.in.)[SOHC- MFI]
E-2.0 dm3(122cu.in.)[DOHC-
MFI]
K-1989
Year
L-1990
Year
M-1991Year
N-
1992
Year
P-1993Year
J-JapanA- Mitsu-
bishr
3- Passen-
9er
Car c-
Auto- matic
Seat Belt
D-Manual
Seat Belt
NOTEl “Check digit” means a single number or letter x used to verify the accuracy of transcription of vehicle identification \
number.
VEHICLE IDENTIFICATION NUMBER LIST
Mlmcc-

VEHICLES FOR FEDERAL
V.I.N. (except sequence number)BrandEngine Displacement Models Code
JA3BR46VnKZMitsubishi Galant
2.0 dm3 (122 cu.in.) E33ASNHEL2M/RHEL2M
JA3BR56VaKZ[SOHC-MFI]
E33ASNXEL2MlFiXEL2M
JA3B R56RaKZ
/
2.0
dm3
( 7 22 cu.in.) [DOHC-MFI]E33ASNGMLZM
TSB Revision

GENERAL - Vehicle Identification00-9
VEHICLES FOR CALIFORNIA
V.I.N. (except sequence number)BrandEngine DisplacementModels Code
JA3BR46VnKZMitsubishi Galant
2.0 dm3 (122 cu.in.1 E33ASNHEL7MIRHEL7M
[SOHC-MFI]
JA3BR56VnKZ E33ASNXEL7MlRXEL7M
I
JA3BR56RC]KZ
2.0
dm3 (122 cu.in.)
[DOHC-MFI] E33ASNGML7M

VEHICLES FOR FEDERAL
V.I.N. (except sequence number)BrandEngine Displacement
Models CodeJASCR46VOl-Z
Mitsubishi2.0
dm3 (122 cu.in.1 E33ASNHEL2MIRHEL2M
Galant
[SOHC-MFI] JA3CR56VOLZ E33ASNXEL2MIRXEL2M
JA3CR56RnLZ2.0 dm3 (122 cuin.)
E33ASNGML2M
[DOHC-MFI]
JA3CX56RnLZMitsubishi E38ASNGML2M
Galant

tAWD>
VEHICLES FOR CALIFORNIA
V.I.N. (except sequence number)
BrandEngine Displacement
Models CodeJA3CR46VC]LZ
Mitsubishi
2.0
dm3 (122 cuin.) E33ASNHEL7MlRHEL7M
Galant
[SOHC-MFI] JA3CR56VC]LZ E33ASNXEL7MIRXEL7M
JA3CR56RnLZ2.0 dm3 (122 cuin.)
E33ASNGML7M
[DOHC-MFI] JA3CX56ROLZ
Mitsubishi E38ASNGML7M
Galant



VEHICLES FOR FEDERAL
V.I.N. (except sequence number) BrandEngine Displacement
Models CodeJA3CR46VC]MZ
Mitsubishi
2.0
dm3 (122 cu.in.1 E33ASNHEL2MlRHEL2M
Galant
[SOHC-MFI]
JA3CR56VnMZE33ASRXEL2M
JA3CR56RnMZ2.0 dm3 (122 cu.in.1[DOHC-MFI]
E33;;$ML2MIRGML2Ml
JA3CX56RnMZMitsubishi E38ASNGML2MlRGML2M
Galant

JA3CX56UOMZ2.0 dm3 (122 cuin.)E39ASNPFL2M [DOHC-MFI-Turbo1
TSB RevisionI

00-l 0
GENERAL - Vehicle Identification
VEHICLES FOR CALIFORNIA
V.I.N. (except sequence number)BrandEngine Displacement
Models Code
JA3CR46VnMZMitsubishi2.0 dm3 (122 cuin.) E33ASNHEL7MIRHEL7M
Galant [SOHC-MFI]JA3CR56VuMZ
E33ASRXEL7M
IJA3CR56RnMZ2.0 dm3 (122 cuin.)[DOHC-MFI]I
FX3;;$ML7MIRGML7M/
I
11 ““nUPi”WD> 200.0~‘~~~22x~.):::::?:;IRGMVM .
1I,J
<1992 MODELS>
VEHICLES FOR FEDERAL
V.I.N. (except sequence number)Brand
JA3CR46VaNZ
JA3CR56VuNZ
JA3CR56RONZ
JA3CX56R[ZlNZ
JA3CX56UnNZ
Mitsubishi1 Galant
MitsubishiGalant
Engine Displacement
2.0
dm3 (122 cu.in.)[SOHC-MFI]
2.0
dm3 (122 cu.in.)[DOHC-MFI]
2.0
dm3 (122 cu.in.)[DOHC-MFI-Turbo]
1 Models Code E33ASNHEL2MIRHEL2M
E33ASRXEL2M
E3gf2N$ML2M/AGML2M/
E38ASNGML2M/RGML2M
E39ASNPFL2M
VEHICLES FOR CALIFORNIA
V.I.N. (except sequence number)
~
I
JA3CR56RnNZ
j Mw;wm;;:1 g;;gwo,
< 1993 MODELS>
VEHICLES FOR FEDERAL
2.0 dm3
(122
cu.in.)
[DOHC-MFI]E33ASNGML7M/RGML7M/ NXML7M
2.0
dms (122 cu.in.)
[DOHC-MFI-Turbo] E39ASNPFL7M
V.I.N. (except sequence number)
BrandEngine Displacement Models Code
JA3DH46DnPZ
JA3DH56DnPZ
Mitsubishi Galant
J,A3DH56EOPZ
2.0 dm3 (122 cu.in.)[SOHC-MFI]
2.0
dm3 (122 win.)[DOHC-MFI] E33ASNXML2M
TSB Revision

GENERAL - Vehicle Identification00-l 1
VEHICLES FOR CALIFORNIA
V.I.N. (except sequence number)
JA3DH46DmPZ
JA3DH56DnPZ
JA3DH56EOPZ
Brand
Mitsubishi Galant
Engine Displacement
2.0
dm3 (122 cu.in.) [SOHC-MFI]
2.0
dm3 (122 cu.in.) [DOHC-MFI]
Models Code E33ASNHEL7M/RHEL7M
b;$,,%&EL7M/NGEL7M/
E33ASNXML7M
VEHICLE INFORMATION
CODE PLATEMOOCD-
Vehicle information code plate is riveted onto the bulkhead in
the engine compartment.
The plate shows model code, engine model, transaxle model, and body color code.
1. MODE
L
2. ENGINE
3. EXT
4. TRANSAXLE
5. COLOR,
INT OPT
E33AS RGELZM
-LzI ~~~~~S$)y& 4G63
( Engine model
CA6
I Exterior co&
F5M22
L Transaxle model
R82 87V 03V
-p+cf~~l;;
CHASSIS NUMBERMOOCE-
STAMPING LOCATION
The chassis number is stamped on the top Center of the
firewall
located in the engine compartment.
CHASSIS NUMBER CODE CHART E33AKZOOOOl
T?T!
1.
Vehicule
line
E-GALANT
2. Engine displacement
33- 2.0 dm3 (122 cu.in.)
engine
3. Body type
A-4-door Sedan
4, Refer to 10th thru 17th digits of V.I.N.
Plate.
K- 1989 models p-l 993 models
L- 1990 models
M-1991 models
N- 199'2 mode\s

GENERAL - Vehicle Identification
OOA0192
Theft protection label
For
orIgInal parts
OOK619
For replacement parts
OOK621
VEHICLE SAFETY CERTIFICATION LABEL MWCF-
1.The vehicle safety certification label is attached to face of left door pillar.
2. This label indicates Gross Vehicle Weight Rating
(G.V.
W.R.), Gross Axle Weight Rating (G.A.W.R.) front, rear and
Vehicle Identification Number
(V.I.N.).
ENGINE MODEL STAMPINGM6ocG-.
1.The engine model number is stamped at the front side on the top edge of the cylinder block as shown in the
following.
Engine model Engine displacement 4G63
2.0
dm3 (122 cu.in.)
2. The engine serial number is stamped near the engine
model number, and the serial number cycles, as shown
below.
THEFT PROTECTION
MwclA9
In order to protect against theft, a Vehicle ldentificatlon
Number
(VIN) is stamped in, or attached as a label to, the
following major parts of the engine and transaxle. as
well as
main outer panels:
Engine cylinder block, Transaxle housing, Fender, Door, Quar-
ter panel, Hood, Trunk lid, Bumpers
In addition, a theft-protection label is attached to replacement
parts for the body outer panel main components, and the same
data are stamped into replacement parts for the engine and the
transaxle.
Cautions regarding panel repairs
1. When repainting original parts, do so after first mask-
ing the theft-protection label, and, after painting, be
sure to peel off the masking tape.
2. The theft-protection label for replacement parts is
covered by masking tape, so such parts can be painted
as is. The masking tape should be removed after
painting is finished.
3.The theft-protection label should not be removed from
original parts or replacement par-&

GENERAL - Vehicle Identification00-13
LOCATIONS
Part
Engine
*ansaxle
.
Target area: for original equipment partsLZZB : for replacement parts
SOHC-Up to 1992 models SOHC-l 993 models
DOHC
Manual transaxle Automatic transaxle

17
1 TSB Revision